Two-stage loading floor system for a vehicle as well as vehicles with such a loading floor system

Abstract

Vehicle (100), which includes: a cargo compartment (100) comprising a two-stage pull-and-push loading floor system (112), wherein the two-stage pull-and-push loading floor system (112) comprises: a first double-rail transition beam element (202) comprising a first rail (302) with an open end (316) and a second rail (304) with an open end (316); a second double-rail transition support element (204) comprising a third rail (302) with an open end (316) and a fourth rail (304) with an open end (316); and a loading floor (206) having a hinge (208) and four pins (318) positioned such that the loading floor (206) can be coupled to the first double-rail transition support element (202) and to the second double-rail transition support element (204) by placing the four pins (318) through the respective open ends (316) in the rails (302, 304) of the first double-rail transition support element (202) and the second double-rail transition support element (204); characterized by the fact that the second rail (304) and the fourth rail (304) each comprise an upper rail section (310), a lower rail section (312) and a middle rail section (314) between the upper rail section (310) and the lower rail section (312); wherein the upper rail section (310) of the second rail (304) extends coplanarly to the first rail (302) and wherein the upper rail section (310) of the fourth rail (304) extends coplanarly to the third rail (302); and wherein the middle rail sections (314) branch off from the upper rail sections (310) at a first angle (A) and the lower rail sections (312) branch off from the middle rail section (314) at a second angle (B) which is greater than the first angle (A).

Description

INTRODUCTION

[0001] The present invention relates to vehicle storage solutions and cargo compartments and in particular to a two-level loading floor system according to the preamble of claim 6, as is essentially known from DE 10 2015 111 703 A1, and to a vehicle with such a loading floor system.

[0002] Further prior art can also be found in the documents EP 2 899 070 A1, EP 1 728 684 A1, JP 2007 / 091105 A, EP 2 008 871 A1, DE 10 2009 025 987 A1, FR 2 949 100 A1, FR 2 890 636 A1 and EP 2 048 031 A1.

[0003] The storage and cargo capacity of a vehicle refers to the areas (volumes) within a vehicle designed or otherwise intended for the storage and transport of various types of cargo, such as luggage, food, equipment, and other belongings of a vehicle occupant. In many vehicles, the majority of the storage and cargo space is located in the one or more trunks, which may be a completely or partially separate, enclosed area at the front and / or rear of the vehicle. Trunks can be flexible in design, for example, with a pass-through opening to the main cabin area (e.g., beyond the rear seats) for longer items such as skis or fishing rods. The design and capacity of a vehicle's cargo compartment can vary greatly depending on the type and size of the vehicle, as well as its use or purpose.

[0004] One type of vehicle storage solution is the two-tier load floor. A two-tier load floor typically consists of a multi-level cargo floor divided into two or more sections, with each section at a different height or level to facilitate loading and unloading of cargo. The so-called "two-tier" load floor refers to the fact that, in the past, the different levels or sections of the load floor were designed to accommodate the varying heights of a towed trailer and the cargo space of a vehicle. The two-tier load floor provides a more consistent and level surface for loading and unloading items, even larger or bulky items such as furniture, appliances, or recreational equipment.

[0005] A two-level load floor design can incorporate features such as removable panels, adjustable platforms, and folding sections that can be configured in various ways to meet the specific needs of the loaded cargo and / or trailer being towed. The two-level load floor offers greater flexibility and convenience when organizing and securing cargo of varying sizes within a vehicle's cargo space.

[0006] The invention is based on the object of providing a vehicle with a two-stage loading floor system and such a two-stage loading floor system that can be operated as intuitively as possible. SUMMARY

[0007] According to the invention, this object is achieved with a vehicle which is characterized by the features of claim 1.

[0008] In addition to one or more of the features described herein, in some embodiments the hinge is a film hinge having a thickness less than that of an upper and a lower portion of the load floor.

[0009] In some embodiments, the first, second, third, and fourth rails include a first end-pin configuration for the four pins and a second end-pin configuration for the four pins. In some embodiments, the load floor can be moved to an upper load floor position by arranging the four pins in the first end-pin configuration. In some embodiments, the load floor can be moved to a lower load floor position by arranging the four pins in the second end-pin configuration.

[0010] In some embodiments, the two-stage pull and push load floor system includes a storage container having a raised portion configured to support one end of the load floor when the load floor is in an upper load floor position.

[0011] Furthermore, the object is achieved according to the invention with a two-stage loading floor system which is characterized by the features of claim 6.

[0012] A method may include providing a first dual-rail transition support member having a first rail with an open end and a second rail with an open end, and providing a second dual-rail transition support member having a third rail with an open end and a fourth rail with an open end. The method may further include coupling a load floor having a hinge and four pins to the first dual-rail transition support member and the second dual-rail transition support member by disposing the four pins through the respective open ends in the respective rails of the first dual-rail transition support member and the second dual-rail transition support member, respectively.

[0013] The above-described features and advantages and other features and advantages of the invention will become apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Further features, advantages and details appear only as examples in the following detailed description, which refers to the drawings; they show: Fig. 1 a vehicle configured according to one or more embodiments; Fig. 2A is a view of a load floor system having a load floor in an upper position according to one or more embodiments; Fig. 2B is a view of a load floor system having a load floor in a lower position according to one or more embodiments; Fig. 3A is a view of a first dual-rail transition support member and a second dual-rail transition support member according to one or more embodiments; Fig. 3B is a view of a loading floor with four pins for insertion into rails of a dual-rail transition support member according to one or more embodiments; Fig. 4A is a view of a load floor system having a load floor in an upper position according to one or more embodiments; Fig. 4B is a view of a load floor system having a load floor in a lower position according to one or more embodiments; Fig. 5A is a plan view of a load floor system according to one or more embodiments; Fig. 5B a view of the loading floor system along section aa in Fig. 5A according to one or more embodiments; and Fig. 6 a flowchart according to one or more embodiments. DETAILED DESCRIPTION

[0015] The following description is merely exemplary in nature. It should be understood that throughout the drawings, corresponding reference numerals indicate similar or corresponding sections and features.

[0016] A vehicle according to an exemplary embodiment is shown in Fig. 1, generally designated 100. The vehicle 100 is depicted in the form of a motor vehicle having a body 102. The body 102 includes a passenger compartment 104 in which a steering wheel, front seats, and rear passenger seats (not separately indicated) are disposed. Disposed within the body 102 are a number of components, including, for example, an electric motor 106 (illustrated by projection under the front hood of the vehicle 100), a battery pack 108 (illustrated by projection under the vehicle 100), and a cargo compartment 110.

[0017] As described in detail herein, the cargo compartment 110 may include a two-stage push-pull load floor system 112 (referred to herein as the load floor system 112). The load floor system 112 is Fig. 1 for illustrative and explanatory purposes only. The configuration, location, size, number, arrangement, etc., of the load floor system 112 are not intended to be particularly limited. Although the present invention is primarily discussed in the context of a rear-mounted storage solution (e.g., in the rear trunk, tailgate, etc., of the vehicle 100), the load floor system 112 need not be so limited and may be used in other areas of the vehicle 100 (e.g., in the front trunk, glove box, etc.). Furthermore, all aspects of the load floor system 112 described herein may be similarly incorporated into any system (vehicle, building, or otherwise) having a multi-level storage solution (e.g., a drawer, chest, cabinet, loading dock or bay, toolbox, etc.), and all such configurations and applications are within the contemplated scope of this invention.

[0018] As previously mentioned, two-level load floors are an excellent storage solution that can allow a user to flexibly move a load floor between two different load floor positions (levels), thus meeting a wide variety of storage requirements. Unfortunately, current load floor solutions are not particularly intuitive for customers, as most configurations require a combination of lifting and removing the load floor to move the load floor from position "A" to position "B." In addition, the load floor often must be grasped from the front edge, creating an overhang that requires the user to reach the entire length of the load floor. To mitigate these problems, some load floor configurations utilize a sill plate so that the user is not forced to apply the full lifting weight required to transition the load floor.

[0019] Due to operational complexity, the transition procedure (i.e., moving a load floor from an 'A' position to a 'B' position) is often explained in detail in a vehicle's owner's manual. This solution is not ideal, as the user must know to consult the owner's manual and may not even be aware that the load floor contains a second function. In addition, current rear load floor solutions require successful cooperation between the rear section and the lower quarter panels, as the lower quarter panels support part of the load floor space. However, the lower quarter panels were not originally designed for this requirement, and a full two-stage load floor solution may require a redesign of the lower quarter panel.

[0020] This invention introduces a new two-stage load floor system that utilizes an intuitive pull-and-push mechanism for transitioning between two load floor positions. To operate the pull-and-push mechanism, a user simply needs to pull in a first (rear) direction and then push in a second (front) direction to change the load floor level. These movements are particularly fluid, simulating a single, continuous sliding motion for the user without requiring the removal of the load floor.

[0021] In some embodiments, the load floor system includes a pair of dual-rail transition support members. In some embodiments, the transition support members can be attached to each front corner of a load floor. In some embodiments, the load floor includes four pins, with each pin configured to move within a specific one of the four tracks of the pair of transition support members. The tracks are designed to provide two end-pin configurations, one for the first load floor level and one for the second load floor level. By moving the pins within the respective tracks between the two end-pin configurations, a user can effortlessly move the load floor between the two levels.

[0022] Two-level load floors with a push-and-pull mechanism constructed according to one or more embodiments offer several technical advantages over other load floor assemblies. In short, the load floors described herein can be easily moved between load floor levels without the user having to remove the load floor or raise the front edge of the load floor above a cantilever. Advantageously, the load floors described herein operate independently of the lower side panel and do not require support from the sill plate. Furthermore, the load floors described herein can meet a variety of loading requirements, such as knee loading and storage, and can be efficiently packed into a storage compartment.

[0023] Fig. 2A and Fig. 2B illustrate representations of a load floor system 112 according to one or more embodiments. The load floor system 112 may be connected to a cargo compartment of a vehicle (e.g., the cargo compartment 110 of the vehicle 100 of Fig. 1) may be coupled or otherwise integrated therewith, although other storage applications (vehicle, structural, or otherwise) are also contemplated within the scope of this invention. In the following sections, the load floor system 112 is shown in the context of the vehicle 100 for explanation and illustration purposes only.

[0024] The load floor system 112 may include a first dual-rail transition support member 202, a second dual-rail transition support member 204, and a load floor 206. In some embodiments, the load floor 206 includes a hinge 208. In some embodiments, the hinge 208 includes a living hinge. A "living hinge" is defined herein as a hinge made of the same material as the two parts it connects. The hinge 208 is not intended to be particularly limited but may, for example, include a relatively thin and flexible portion 210 disposed between a first portion 212 and a second portion 214 of the load floor 206. As used herein, the "relatively thin" and flexible portion 210 refers to the portion 210 whose thickness is less than the thickness of the first portion 212 and the thickness of the second portion 214 of the load floor 206.The first double rail transition support member 202 and the second double rail transition support member 204 are described with reference to FIG. Fig. 3A in more detail. The loading floor 206 is described with reference to Fig. 3B is explained in more detail.

[0025] Fig. 2A shows the load floor system 112 with the load floor 206 in an upper position (i.e., a first level or position "A"). As shown in Fig. As shown in Figure 2A, the load floor system 112 may further include a storage container 216 over which the load floor 206 rests when in the raised position. In some embodiments, the load floor system 112 and / or the storage container 216 include a raised portion 218 configured to support an end 220 of the load floor 206 in the raised position.

[0026] Fig. 2B shows the load floor system 112 with the load floor 206 in a lower position (i.e., a second level or position "B"). As shown in Fig. 2B, the loading floor 206 may define a bottom surface of the storage container 216 in the lower position. In some embodiments, the raised portion 218 and / or the loading floor 206 are configured such that the end 220 of the loading floor 206 abuts the raised portion 218 in the lower position.

[0027] Fig. 3A shows a view of the first dual-rail transition support member 202 and the second dual-rail transition support member 204 according to one or more embodiments. For ease of illustration and discussion, various elements of the first dual-rail transition support member 202 and the second dual-rail transition support member 204 are described solely with reference to the first dual-rail transition support member 202. However, the second dual-rail transition support member 204 may include matching elements. That is, the first dual-rail transition support member 202 and the second dual-rail transition support member 204 may be substantially identical.

[0028] In some embodiments, the first dual-rail transition support member 202 includes a first rail 302 and a second rail 304 configured and arranged as shown. In some embodiments, the second rail 304 includes an upper rail portion 310, a lower rail portion 312, and a middle rail portion 314 between the upper rail portion 310 and the lower rail portion 312. For clarity, only the upper rail portion 310, the middle rail portion 314, and the lower rail portion 312 for the second rail 304 are shown separately. In some embodiments, the upper rail portion 310 for the second rail 304 is coplanar (or substantially coplanar within the tool limits) with the first rail 302.

[0029] In some embodiments, the middle rail section 314 for the second rail 304 extends from the upper rail section 310 at a first angle A and the lower rail section 312 extends from the middle rail section 314 at a second angle B that is greater than the first angle A. As shown in Fig. 3A, the first angle A is between about 70 and 110 degrees, for example 90 degrees, although other configurations are also contemplated within the scope of this invention. As shown in Fig. 3A, the second angle B is between about 90 and 160 degrees, for example 120 degrees, although other configurations are also contemplated within the scope of this invention.

[0030] In some embodiments, each of the rails 302 and 304 includes an open end 316. In some embodiments, each open end 316 is sized to receive a pin 318 of the load floor 206. Fig. 3B shows a view of the load floor 206 with four pins 318 configured for insertion into the rails 302 and 304 via the open ends 316. In some embodiments, the four pins 318 have a first inner diameter that is less than the width of the open ends 316, a second outer diameter that is greater than the width of the open ends 316 and a height of the rails 302 and 304. In this manner, insertion of the four pins 318 into the respective open ends 316 serves to connect the load floor 206 to the first dual-rail transition support member 202 and the second dual-rail transition support member 204.

[0031] Fig. 4A shows the load floor system 112 with the load floor 206 in an upper position (i.e., a first level or position "A"). As shown in Fig. 4A, the rails 302 and 304 are designed to provide an end-pin configuration for two of the four pins 318 in the upper position. In some embodiments, to adjust the "A" position, the load floor 206 may be pushed toward the first dual-rail transition support member 202 and the second dual-rail transition support member 204 until the pins 318 reach the respective first end positions 402 in the rails 302 and 304 (as shown in Fig. 4A).

[0032] As in Fig. 4A, in some embodiments, the hinge 208 is configured such that the load floor 206 can be positioned in a first orientation (as shown, in a horizontal orientation) and in a second orientation (as shown by projection, in a vertical orientation) when the load floor 206 is in position "A". In this way, the load floor 206 can be adjusted such that an underlying cargo space, such as the storage container 216 in Fig. 2A, is exposed or covered.

[0033] Fig. 4B shows the load floor system 112 with the load floor 206 in a lower position (i.e., a second level or position "B"). As shown in Fig. 4B, the rails 302 and 304 are designed to provide an end-pin configuration for two of the four pins 318 in the lower position. In some embodiments, to set the "B" position, the load floor 206 may be pulled in a direction away from the first dual-rail transition support member 202 and the second dual-rail transition support member 204 until the pins 318 in the second rail 304 and the fourth rail 308 drop into the lower rail portion 312. The load floor 206 may then be pushed toward the first dual-rail transition support member 202 and the second dual-rail transition support member 204 until the pins 318 reach the respective second end positions 404 in the rails 302, 304, 306, and 308 (as shown in Fig. 4B).

[0034] To return to position “A” (see Fig. 4A), the steps are simply performed in reverse order. That is, the loading floor 206 can be pulled away from the first dual-rail transition support member 202 and the second dual-rail transition support member 204, and the loading floor 206 can be lifted to insert the pins 318 into the upper rail section 310. Once the pins 318 are within the upper rail section 310, the loading floor 206 can be pushed toward the first dual-rail transition support member 202 and the second dual-rail transition support member 204 until the pins 318 reach the respective first end positions 402 in the rails 302, 304, 306, and 308 (as in Fig. 4A).

[0035] Fig. 5A shows a top view of a load floor system 112 according to one or more embodiments. Fig. 5B shows a view of the loading floor system 112 along section aa in Fig. 5A according to one or more embodiments. In some embodiments, the first dual-rail transition support member 202 and the second dual-rail transition support member 204 (not shown separately) include a load floor mount 502. In some embodiments, the load floor mount 502 includes one or more anchors 504 (also referred to as pins).

[0036] In some embodiments, the load floor support bracket 502 extends from the first dual-rail transition support member 202 (or the second dual-rail transition support member 204) such that the load floor 206 may partially rest on the load floor support bracket 502 when the pins 318 are inserted into the rails 302, 304, 306, and 308 (see Fig. 4A and Fig. 4B). In some embodiments, the one or more anchors 504 extend into recesses (not separately shown) in the load floor 206 to secure the load floor 206 to the load floor mount 502. In some embodiments, the load floor mount 502 is configured to support the weight of the load floor 206. In some embodiments, the load floor mount 502 and the raised portion 218 of the storage container 216 (see Fig. 2A) are configured so that together they support the weight of the loading floor 206.

[0037] As in Fig. 6, a flowchart 600 for a two-stage load floor with a push-pull mechanism constructed in accordance with one or more embodiments is shown generally in accordance with one embodiment. The flowchart 600 is described with reference to Fig. 1 to 5B and may include additional steps described in Fig. 6 are not shown. Although shown in a specific order, the Fig. 6 blocks shown can be rearranged, divided and / or combined.

[0038] In block 602, a first dual-rail transition support member is provided. The first dual-rail transition support member includes a first rail with an open end and a second rail with an open end. In block 604, a second dual-rail transition support member is provided. The second dual-rail transition support member includes a third rail with an open end and a fourth rail with an open end.

[0039] In block 606, a load floor is coupled to the first dual-rail transition support member and the second dual-rail transition support member. In some embodiments, the load floor includes a hinge and four pins. In some embodiments, the load floor is coupled to the first dual-rail transition support member and the second dual-rail transition support member by inserting the four pins through the respective open ends into the corresponding rails of the first dual-rail transition support member and the second dual-rail transition support member.

[0040] In some embodiments, the hinge is a film hinge having a thickness less than that of an upper and a lower portion of the loading floor.

[0041] In some embodiments, the second rail and the fourth rail each include an upper rail portion, a lower rail portion, and a middle rail portion between the upper rail portion and the lower rail portion. In some embodiments, the upper rail portions are coplanar with the first rail and the third rail, the middle rail portions extend from the upper rail portions at a first angle A, and the lower rail portions extend from the middle rail portion at a second angle B that is greater than the first angle A.

[0042] In some embodiments, the first, second, third, and fourth rails include a first end-pin configuration for the four pins and a second end-pin configuration for the four pins. In some embodiments, the load floor can be moved to an upper load floor position by inserting the four pins into the first end-pin configuration, and the load floor can be moved to a lower load floor position by inserting the four pins into the second end-pin configuration.

[0043] In some embodiments, the two-stage pull and push load floor system includes a storage container having a raised portion configured to support one end of the load floor when the load floor is in an upper load floor position.

Claims

[1] Vehicle (100) comprising: a cargo compartment (100) comprising a two-stage pull-and-push loading floor system (112), the two-stage pull-and-push loading floor system (112) comprising: a first dual-rail transition support member (202) having a first rail (302) with an open end (316) and a second rail (304) with an open end (316); a second double-rail transition support member (204) having a third rail (302) with an open end (316) and a fourth rail (304) with an open end (316); and a loading floor (206) having a hinge (208) and four pins (318) positioned so that the loading floor (206) can be coupled to the first dual-rail transition support member (202) and to the second dual-rail transition support member (204) by arranging the four pins (318) through the respective open ends (316) in the rails (302, 304) of the first dual-rail transition support member (202) and the second dual-rail transition support member (204); characterized by , that the second rail (304) and the fourth rail (304) each comprise an upper rail section (310), a lower rail section (312) and a middle rail section (314) between the upper rail section (310) and the lower rail section (312); wherein the upper rail portion (310) of the second rail (304) extends coplanar with the first rail (302) and wherein the upper rail portion (310) of the fourth rail (304) extends coplanar with the third rail (302); and wherein the middle rail sections (314) extend from the upper rail sections (310) at a first angle (A) and the lower rail sections (312) extend from the middle rail section (314) at a second angle (B) which is greater than the first angle (A). [2] The vehicle (100) of claim 1, wherein the hinge (208) comprises a film hinge having a thickness less than the thickness of an upper portion and the thickness of a lower portion of the loading floor (206). [3] The vehicle (100) of claim 1, wherein the first, second, third and fourth rails (302, 304) comprise a first end pin configuration for the four pins (318) and a second end pin configuration for the four pins (318). [4] The vehicle (100) of claim 3, wherein the load floor (206) is movable to an upper load floor position by arranging the four pins (318) in the first end pin configuration, and the load floor (206) is movable to a lower load floor position by arranging the four pins (318) in the second end pin configuration. [5] The vehicle (100) of claim 1, further comprising a storage container (216) having a raised portion (218) configured to support an end (316) of the load floor (206) when the load floor (206) is in an upper load floor position. [6] Two-stage pull and push loading floor system (112) comprising: a first dual-rail transition support member (202) having a first rail (302) with an open end (316) and a second rail (304) with an open end (316); a second double-rail transition support member (204) having a third rail (302) with an open end (316) and a fourth rail (304) with an open end (316); and a loading floor (206) comprising a hinge (208) and four pins (318) positioned so that the loading floor (206) can be coupled to the first dual-rail transition support member (202) and to the second dual-rail transition support member (204) by arranging the four pins (318) through the respective open ends (316) in the rails (302, 304) of the first dual-rail transition support member (202) and the second dual-rail transition support member (204); characterized by , that the second rail (304) and the fourth rail (304) each comprise an upper rail section (310), a lower rail section (312) and a middle rail section (314) between the upper rail section (310) and the lower rail section (312); wherein the upper rail portion (310) of the second rail (304) extends coplanar with the first rail (302) and wherein the upper rail portion (310) of the fourth rail (304) extends coplanar with the third rail (302); and wherein the middle rail sections (314) extend from the upper rail sections (310) at a first angle (A) and the lower rail sections (312) extend from the middle rail section (314) at a second angle (B) which is greater than the first angle (A). [7] The two-stage pull-push load floor system (112) of claim 6, wherein the hinge (208) comprises a film hinge having a thickness less than the thickness of an upper portion and the thickness of a lower portion of the load floor (206).

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